How to Cut Aluminum Extrusion

Aluminum extrusions are lightweight strong and highly customizable materials used across industries such as construction transportation and automation systems Cutting aluminum extrusion accurately is essential for quality assembly and long term performance

This guide provides a complete overview of how to cut aluminum extrusion safely and precisely with the right tools techniques and precautions Whether you are a hobbyist a machinist or a fabricator this article by sasaaluminum offers practical advice you can apply immediately

What Are Aluminum Extrusions

Aluminum extrusions are profiles made by forcing heated aluminum alloy through a shaped die resulting in a continuous cross sectional shape Common profiles include channels angles t slots square tubes and custom frames

Alloys like 6061 and 6063 are frequently used due to their machinability and strength

Tools Suitable for Cutting Aluminum Extrusions

Different cutting tools serve different needs Choose based on accuracy budget and workload

Miter Saw
Ideal for precise straight or angled cuts when equipped with a blade designed for non ferrous metals

Band Saw
Suitable for larger or thicker profiles often used in workshops and industrial settings

Cold Saw
Delivers clean burr free cuts using coolant to reduce heat buildup

Jigsaw
Useful for irregular cuts or field work when mobility is required

Hacksaw
Manual and cost effective suitable for occasional use or thin profiles

CNC Router
For professional applications requiring perfect cuts with minimal manual effort

Step by Step How to Cut Aluminum Extrusion

Step 1 Choose the right tool and blade
Use a carbide tipped blade designed for aluminum or non ferrous metals Avoid wood blades

Step 2 Secure the material
Clamp the extrusion firmly to avoid shifting during cutting

Step 3 Mark the cut
Use a ruler and marker to define the exact location and angle of the cut

Step 4 Lubricate if needed
Cutting wax or oil reduces heat and friction for smoother results

Step 5 Make the cut
Cut slowly and steadily Allow the blade to work without forcing it

Step 6 Deburr the edges
Use a file or sandpaper to remove sharp burrs or edges from the cut area

Safety Tips When Cutting

• Wear safety glasses and gloves

• Avoid loose clothing around spinning blades

• Use hearing protection with power saws

• Keep work area clean and well lit

Common Mistakes to Avoid

• Using incorrect blades

• Cutting too fast and overheating the blade

• Failing to clamp material securely

• Skipping the deburring step

• Not wearing personal protective gear

Choosing the Right Extrusion Alloy

Popular alloys for extrusion include

6063 for architectural or decorative uses
6061 for structural strength and machinability
6082 for high strength applications in construction or machinery

sasaaluminum offers cutting services and expert selection guidance to match your application

Industries That Require Precision Cutting

• Solar panel racking systems

• Assembly lines and t slot framing

• Aerospace and automotive prototypes

• DIY shelving and cabinetry

• Robotics enclosures and automation guides

Why Buy from sasaaluminum

sasaaluminum provides high quality aluminum extrusion products with custom cutting services All materials are processed with precision and shipped securely to meet industrial or DIY customer needs

Our services include

• Custom length cutting

• Deburring and packaging

• Quick delivery

• Alloy consulting support

Conclusion

Cutting aluminum extrusion is simple when done with the right blade proper setup and safety measures From industrial machinery frames to home projects clean and accurate cuts ensure perfect assembly

For reliable aluminum extrusion products and custom cutting support turn to sasaaluminum your partner in precision aluminum solutions